So, Bessy has been making a little noise, which I thought the primary need adjusted, it was loose, so I adjusted it and went on my merry way! Things were great for a few days. Only around 1500 miles on the new 90" build, just got a new tire a couple days prior so i was finally getting traction. Then.... i shifted from 3rd to 4th and it locked up for a second, broke free, and then no more go... fast track getting her home and tearing her apart.

Tearing her down I find the crankshaft is toast. Not in the usual location that they snap from what I am hearing, but just behind the splines where it passes through the stator.

Anyone have any experience, advice, or suggestions on a new crank? Type, brand, etc?

Motor was built by NRHS and is top shelf. Speaking with them, they've not really seen any cranks snap in the location mine did... they told me they usually snap around the connecting rods. I've asked about the benefits of me updating to a buell crank, and was told that it's not going to be a silver bullet for my problem. That the part that is beefed up on those vs mine is not the area I need to be addressing. I will try to attach some pics of my findings. My first post! Any advice is welcomed!

Tearing her down I find the crankshaft is toast. Not in the usual location that they snap from what I am hearing, but just behind the splines where it passes through the stator.

That shaft is called the "sprocket shaft", as opposed to the "pinion shaft" which is on the other side of the crank.

Failures of the sprocket shaft are not terribly unusual on the stock cranks, I've seen several of them.

The 08+ Buell/XR1200 crank is the ticket to solving this problem.

As you can see, they substantially upgraded the sprocket shaft. The whole reason behind that was to prevent the failure you suffered.

Here's what you need ...

23999-08 3.813 stroke flywheel assembly

Front sprocket/rotor assembly:

30029-08 38T version for use with 96-link primary chain 40147-04 (1200) - note that you already have this chain

30018-08 34T version for use with 94-link primary chain 40005-57B (883) - going to this sprocket and chain instead would shorten your gearing

4589 bolt

6445 washer

Also, I suggest the SE heavy duty sprocket shaft bearing while you're in there, part number 24004-03B. The dealers will try to tell you it's a Twin Cam part. Ignore them, it fits XL's too. XL's and Twin Cams use the same sprocket shaft bearing.

Go to one of the many online discount dealers to order these parts, you'll get a much better price than your local dealer, and better than we can give you too (we have to charge list on HD parts). I suggest Surdyke.com for example. You will be surprised at how reasonably priced this stuff is.

For anyone with a 91-03 model reading this, this crank does not fit your motor without machine work and special pieces. We offer an upgrade service where we fit this crank to your motor. In this service we do all the machining and supply all the parts and assemble the lower end for you, with new sprocket shaft and pinion bearings, a new outer pinion race pressed in and line-lapped, and the flywheel end play set.

New Castle HD will have better prices than Surdyke but Surdyke will offer free shipping,too bad the crank is too heavy for that deal.
Surdyke also doesnt sell anything that costs under 10.00 over the internet so New Castle might be the overall better deal.
Shop them both !

I put this crank in after a failure on a 90" 2008 Nightster build. Though my failure point was different from your own (and avoidable). So, I was interested to read your story with those parallels and curious about your build and your misfortune. Curious about the other elements of your build too if you want to share.

In my initial build I'd chosen against upgrading the crank partly due to the low rpm characteristics of the lighter flywheel and, of course, budget. Ended up choosing it over a stock crank replacement for all the advantages Aaron listed above. But, long story short, I really like the crank and am happy with the outcome now that the rebuild pain has passed.

Anyway, not sure whether you've hung around at XLF after posting your thread, but really hope you are back on the road soon.

Boardtracker hd is cheaper than new castle I have found. That is if they still sell online they used to be another name. New castle charges alot to ship stuff but there processed are usually lower which sometimes is a trade off and so eti es makes there prices to much.